Installation Procedure to Retrofit Overhead Guard and Front Window Guard Upgrade Kits on the Cab of Certain Large Excavators and Mobile Hydraulic Power Units {7159} Caterpillar

Excavator

365C (S/N: ELC1-UP; MEM1-UP; FEN1-UP; PAR1-UP; MCS1-UP; MCY1-UP)

374D (S/N: PJA1-UP; PAP1-UP; PAS1-UP; PAX1-UP)

385C (S/N: EDA1-UP; KGB1-UP; KBC1-UP; SBE1-UP; T2E1-UP; T2F1-UP; KKK1-UP; JCM1-UP; MNZ1-UP)

390D (S/N: WAG1-UP; BYP1-UP; WAP1-UP; WBT1-UP; KCZ1-UP)

Front Shovel

385C (S/N: MMA1-UP; EAM1-UP)

Mobile Hydraulic Power Unit

325D MHPU (S/N: SRC1-UP; C3N1-UP)

330D MHPU (S/N: GMN1-UP)

345C MHPU (S/N: B6N1-UP)

345D MHPU (S/N: P5D1-UP)

365C MHPU (S/N: GSZ1-UP)

374D MHPU (S/N: JNZ1-UP)

385C MHPU (S/N: M4E1-UP)

Introduction

This Special Instruction outlines the installation procedure to retrofit a 471-1994 Overhead Guard Kit and a 471-1993 Guard Kit on the cab of certain Large Excavators and Mobile Hydraulic Power Units listed above.

Do not perform any of the procedures or order any parts until you have read and understand the instructions contained in this publication.

Safety Section

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Do not operate or work on this machine unless you have read and understand the instructions and warnings in the Operation and Maintenance Manuals. Failure to follow the instructions or heed the warnings could result in injury or death. Contact your Cat dealer for replacement manuals. Proper care is your responsibility.

Parts List

Machine Preparation

Illustration 1	g02280104

1. Park the machine on a level surface. Refer to the appropriate Operation and Maintenance Manual, "Parking" for the proper procedure.

2. Make sure that all mounting surfaces are clean and free of debris.

Installation Procedure

471-1994 Overhead Guard Kit

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Illustration 2	g03745398
(21) Screw (22) Washer (23) Cover (24) Cover (25) Bolt (26) Washer (27) Rubber washer

1. Remove four screws (21) and four washers (22).

2. Remove left-hand cover (23) and right-hand cover (24).

3. Remove two bolts (25), two washers (26), and two rubber washers (27).
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   Illustration 3	g03745401
   (28) Bolt (29) Hard Washer (30) Bracket As (31) Flood Lamp Gp (32) Bolt (33) Hard Washer (34) Bracket As (35) Flood Lamp Gp

4. Remove two bolts (28) and two hard washers (29).

5. Remove left-hand bracket assembly (30) with flood lamp group (31).

6. Remove two bolts (32) and two hard washers (33).

7. Remove right-hand bracket assembly (34) with flood lamp group (35).
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   Illustration 4	g03745404
   (1) 6C-8787 Tube (2) 7X-2475 Bolt (3) 7X-2552 Bolt (4) 7Y-5227 Bolt (5) 9X-8257 Washer (6) 090-8865 Spacer (7) 193-2153 Guard As (8) 219-0305 Film (9) 266-0545 Film

8. Install guard assembly (7) and tighten two sets of bolts (2), tube (1), spacer (6), and two sets of bolts (4), tube (1), and spacer (6).

9. Tighten two sets of bolts (3) and washers (5).

10. Apply film (8) and film (9) on guard assembly (7).
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    Illustration 5	g03745407
    (14) 8T-4970 Bolt (16) 9X-8256 Washer (18) 167-3441 Flood Lamp Gp (19) 198-1659 Support (20) 198-6223 Lighting Harness As

11. Install a support (19) to a flood lamp group (18) by tightening two sets of bolts (14) and washers (16).

12. Connect a lighting harness assembly (20) to flood lamp group (18) and insert the other side of the lighting harness into the cab.
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    Illustration 6	g03745416
    (10) 7K-1181 Cable Strap (11) 8T-4121 Hard Washer (12) 8T-4133 Nut (13) 8T-4136 Bolt (15) 9H-1024 Hard Washer (17) 142-8545 Bolt

13. Secure support (19) with flood lamp group (18) to the front right-hand corner of guard assembly (7) by using bolt (13), two hard washers (11), and nut (12).

14. Bundle lighting harness assembly (20) using two cable straps (10).

15. Tighten bolt (17) and hard washer (15).

16. Repeat Steps 11 through 15 for installing a flood light group (18) on the front left-hand side of guard assembly (7).

471-1993 Guard Kit

Illustration 7	g03743815
(1) 4E-1384 Conical Bumper (2) 5C-7261 Nut (3) 6C-8379 Latch As (4) 6C-8382 Latch Spring (5) 7Y-0623 Locknut (6) 8T-4139 Bolt (7) 8T-4183 Bolt (8) 8T-4223 Hard Washer (9) 8T-4224 Hard Washer (10) 8T-4910 Bolt (11) 9X-8257 Washer (12) 096-4882 Locknut (13) 115-1624 Gas Spring As (14) 141-6518 Spacer (15) 188-8843 Plug (16) 191-2752 Bracket As (17) 191-2753 Bracket As (18) 191-6243 Spacer (19) 194-0715 Spacer (20) 199-3680 Handle As (21) 201-4534 Bolt (22) 201-4535 Pin (23) 219-0305 Film (24) 241-4052 Support As (25) 241-4053 Support As (26) 266-0546 Film (27) 331-9373 Window Guard As

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Illustration 8	g03744106
(10) 8T-4910 Bolt (14) 141-6518 Spacer (18) 191-6243 Spacer (19) 194-0715 Spacer (24) 241-4052 Support As (25) 241-4053 Support As

1. Install support assembly (25) by using one bolt (10), one spacer (14), and one spacer (18), and one spacer (19) on the top right cab front frame.

2. Install support assembly (24) by using one bolt (10), one spacer (14), and one spacer (18), and one spacer (19) on the top left cab front frame.
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   Illustration 9	g03744146
   (3) 6C-8379 Latch As (4) 6C-8382 Latch Spring (8) 8T-4223 Hard Washer (9) 8T-4224 Hard Washer (10) 8T-4910 Bolt (12) 096-4882 Locknut (16) 191-2752 Bracket As (18) 191-6243 Spacer (22) 201-4535 Pin

3. Install bracket assembly (16) by using two bolts (10) with two hard washers (8) and two spacers (18) on the bottom right cab front frame.

4. Install one latch assembly (3) with one latch spring (4) on bracket assembly (16) and secure by using pin (22), two hard washers (9) and one locknut (12).
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   Illustration 10	g03744184
   (3) 6C-8379 Latch As (4) 6C-8382 Latch Spring (8) 8T-4223 Hard Washer (9) 8T-4224 Hard Washer (10) 8T-4910 Bolt (12) 096-4882 Locknut (17) 191-2752 Bracket As (18) 191-6243 Spacer (22) 201-4535 Pin

5. Install bracket assembly (17) by using two bolts (10) with two hard washers (8) and two spacers (18) on both bottom left cab front frame.

6. Install one latch assembly (3) with one latch spring (4) on a bracket assembly (17) and secure by using pin (22), two hard washers (9) and one locknut (12).
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   Illustration 11	g03744206
   (6) 8T-4139 Bolt (8) 8T-4223 Hard Washer (15) 188-8843 Plug (20) 199-3680 Handle As (27) 331-9373 Window Guard As

7. Before installing window guard assembly (27) to the cab, install handle assembly (20).

8. Install handle assembly (20) by using two bolts (6) and two hard washers (8).

9. Install two plugs (15) into both the top and bottom hole of handle assembly (20).
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   Illustration 12	g03745204
   (A) Handle assembly position during working (B) Handle assembly position for shipping, storage, and MH applications

   Note: Handle assembly (20) should be positioned for shipping, storage, and MH applications as shown in Illustration 12.

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   Illustration 13	g03744228
   (1) 4E-1384 Conical Bumper (2) 5C-7261 Nut (9) 8T-4224 Hard Washer

10. Install a conical bumper (1) on both sides of the guard assembly using a hard washer (9) and a nut (2).
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    Illustration 14	g03745281
    (5) 7Y-0623 Locknut (11) 9X-8257 Washer (21) 201-4534 Bolt (24) 241-4052 Support As (not shown) (25) 241-4053 Support As

11. Install window guard assembly (27) on the cab. The weight of the window guard assembly is approximately 67.7 kg (149.3 lb).

12. Secure the window guard assembly to support assembly (25) and support assembly (24) (not shown) using two bolts (21), two washers (11) and two locknuts (5).
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    Illustration 15	g03745322
    (2) 5C-7261 Nut (13) 115-1624 Gas Spring As (16) 191-2752 Bracket As (17) 191-2753 Bracket As (not shown)

13. Install one gas spring assembly (13) on the lower right-hand side and lower left-hand side of the window guard assembly. The top of each gas spring assembly is secured to the window guard assembly by using a nut (2).

14. The bottom of the gas spring assembly on the right-hand side is secured to bracket assembly (16) using a nut (2).

15. The bottom of the gas spring assembly on the left-hand side is secured to bracket assembly (17) (not shown) using a nut (2).
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    Illustration 16	g03744228

16. Loosen nuts (2). Adjust conical bumper (1) position in order to prevent rattles when the window guard assembly is latched.

17. Tighten nuts (2) in order to secure the conical bumper at the appropriate position.
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    Illustration 17	g03745375

18. Apply film (23) and film (26) at the locations shown in Illustration 17.

Film Installation

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Avoid prolonged skin contact with isopropyl alcohol. Avoid breathing the vapors in enclosed areas without adequate ventilation and do not smoke. Isopropyl alcohol is flammable. Do not use near open flame, welding operations, or around heated surfaces exceeding 482°C (900°F).

Surface preparation is important in the installation of films. The surface must be clean and dry in order for the films to adhere to the machine. Be sure that oil, grease, and dirt have been removed before you install the new films. The installation instructions that follow are recommended:

1. A 50:50 mixture of isopropyl alcohol and water is generally an adequate cleaning agent for cleaning the mounting surface.

2. Apply solvent to the contact area. Wipe the surface with a lint free cloth until the surface is dry.

3. Carefully remove the liner from the back of the film. Avoid touching the adhesive.

4. Apply the film to the surface.

   Note: The film cannot be repositioned once the film is applied. If the film is installed incorrectly, the film must be removed and discarded. Start again and use a new film.

5. Press the film firmly into place. Apply pressure evenly across the entire surface of the film. The use of a hand roller or a squeegee is recommended in order to ensure maximum adhesion to the mating surface. Remove any bubbles that remain under the film.